AMORPHOUS ALKALI METAL SILICATE, PROCESS AND USES

Abstract: A particulate amorphous alkali metal silicate is prepared by heating a mixture of silicate glass and water or aqueous solution to a temperature of about 300 to 400 DEG C to provide a foamed material that is easily formed into particles of less that about 20 microns. After careful hydration, a product having 0.5 to 15 % water based on loss of ignition (LOI) of product at 800 DEG C is produced that controls the activity of magnesium in solution and is, therefore, a useful detergent ingredient.

Description: AMORPHOUS ALKALI METAL SILICATE, PROCESS AND USES BACKGROUND OF THE INVENTION This invention relates to amorphous alkali metal silicate particles of controlled hydration and solubility, a process for making the silicate, and uses thereof, 5 especially for detergents and cleaning products. In par¬ ticular, the invention involves a process of heating a mixture of alkali metal silicate glass and water to provide an expanded silicate product which is easy to form into particles. The resultant particulate product, when hy- 10 drated, provides excellent properties as a detergent ingredient. Alkali metal silicates are articles of commerce that have been produced for over 100 years and are used in numerous industrial and consumer products. These products, 15 usually sodium or potassium silicates, are available in various forms: solutions, anhydrous glasses, hydrated solids and hydrated or anhydrous crystals. The preparation of hydrated solid silicates, either crystalline or amor¬ phous, presents some difficulty since the products are 20 hygroscopic and tend to cake. Non-crystalline (i.e., amorphous) products are com¬ monly prepared by dissolving a silicate glass and spray drying the resulting solution. The product consists of small spheres, some of which are hollow. The water content 25 must be carefully controlled to a narrow range around 20%. If the moisture content is too high, the product will cake; if it is too low, dissolution is difficult. Several attempts have been made to prepare a product that is somewhat different by heating a silicate 30 solution under pressure to temperatures considerably above boiling and then injecting the solution into a zone of reduced pressure. Water is removed without further heating and an expanded silicate is realized. See British Patent 788,933 (1958) and U.S. Patent 3,450,494 (1969). These 35 materials have not been found to be useful. These methods all have the disadvantage that silicate glass must be dissolved and then dried under rather exacting conditions to provide a useful product. It would be desirable to hydrate glasses directly to provide the product, thereby eliminating the solution step and the costly spray drying step. It would also be desirable to form a product from such a process having lower water content (<15%) since such products are more stable for storage and use. Various methods of hydrating silicate glass to provide stable products have been attempted. U.S. Patent 3,782,906 suggests hydrating and agglomerating alkali metal silicate glass in a fluid bed wherein the expansion gas is steam. This process and product have not found acceptance by silicate producers or by silicate users. It is an object of this invention to provide a process for producing a non-crystalline alkali metal sili¬ cate that does not cake, with a controlled water content so that the solubility and other properties are controlled. In particular, the product of our process provides desir- able properties to the detergent industry. It is also an object of this invention to provide a process for preparing a finely divided hydrated silicate that does not require dissolution of the glass and spray drying. SUMMARY OF THE INVENTION The process required to provide the particulate hydrated amorphous alkali metal silicate product of our invention is surprisingly simple when compared to the pro¬ cesses of the prior art. In accordance with the invention, alkali metal silicate glass particles are mixed with water or various solutions; the mixture is heated under condi¬ tions that induce foaming and expansion within about 5 to 30 minutes after the mixture attains about 300°C or more. This foamed and expanded material is easily processed by shattering, milling, etc. to particles of less than 20 microns to provide the stable powdered product. The water content is controlled and/or adjusted to a range between 0.5% and 15% to provide the desired properties. The invention product provides excellent magnesium ion removal from solutions and can sorb large amounts of liquids such as surfactants, so that it is a desirable ingredient for various detergents and cleaning compositions. The preparation of the amorphous product of the invention is surprising since the glass/water mixture is heated at temperatures of about 300 to 400°C, and cryst¬ alline materials such as sodium metasilicate and sodium disilicate, among others, are known to form at such temperatures. See Tuttle and Frieman, JACS, 70, 919-926 (March 1948) and Rowe, Fournier and Morey, Inorganic Chemistry 6, 3 1183-1888 (1967) . Our process and product solve one of the most important and persistent problems associated with providing alkali metal silicates as powders. Present commercial methods to provide such products involve drying or crystal¬ lization from a solution, and removal of sufficient water to provide uniform and stable materials is difficult as well as expensive. These products are also unstable in that they cake readily when they are exposed to moisture variation or temperature cycles. If a spray-dried silicate containing the usual 18 to 20% moisture is subjected to just 2 cycles of increased temperature followed by return to ambient temperature, sufficient caking to render the product useless can take place. The product of our process is not dried from a solution, and only sufficient water is added to the final product to provide the desired properties. Such a product provides much greater stability to humidity and temperature variations. THE INVENTION The glass required for the invention process is sodium and/or potassium silicate. Such glasses are formed by the fusion of sources of the alkali metal and silica. Sodium and/or potassium carbonate is fused with sand to provide the molten glass which is processed to provide an appropriate particle size. Various methods can be used following foaming to produce the particles required, such as rapid cooling of the glass and grinding or milling. The glass used in our process contains 1.5 to 4.0 moles of Si0 2 for each mole of M 2 0. M can be sodium and/or potassium. The ground glass particles required for the invention process can be any size that allows formation of a uniform mixture when combined with water. Satisfactory products have been prepared using anhydrous glass with a particle size range between 60 and 250 micrometers (μm) . The particles of anhydrous glass are mixed with water or an aqueous solution, thereby forming a mixture. The solution can be sodium and/or potassium hydroxide, or sodium and/or potassium silicate or a mineral acid solution. Sufficient water or aqueous solution is used so that the anhydrous glass mixture contains 5 to 20% water. The heat generated by mixing can provide a temperature of 20 to 30°C. The mixture can be further heated immediately after mixing, or it can be stored for 24 hours or more prior to heating to foaming conditions. It is preferred to heat the mixture within about 30 minutes of preparation. The mixture is heated in the foaming step to a temperature between about 300°C and about 400°C for sufficient time to provide formation of a foam. If the temperature is too low, the expansion by foaming will not be sufficient to provide a product with the required properties. If the temperature is above about 400°C, undesirable crystalline species form. The foam is produced about 8 to 30 minutes after attaining a temperature in the range of about 300 to about 400°C. The rate at which the mixture is heated to about 300 to about 400°C does not appear to be critical. The foamed material is removed from the heat and cooled to about room temperature. The cooled foam is easily shattered to form small particles of less than 20 microns. The foamed and expanded silicate and the particles realized from it are essentially anhydrous (less than 1% by weight water) . In this state, the product is not effective as a detergent ingredient. In particular, the product does not provide adequate reduction of magnesium activity in a wash bath. Therefore, an additional process step is generally required in which the foamed and powdered mate¬ rial is exposed to water in such a manner that the water is incorporated into or on the silicate particles in such a way that the product does not cake. For example, the partially powdered foam can be treated in an air mill using moist air, or the powdered product can be hydrated in a fluid bed using moist air for expansion. The product useful for detergents must contain at least 0.5% water to be effective and can contain up to 15%. If it contains more than 15% water, the product is prone to caking. The preferred product contains 1 to 12% moisture as determined by loss on ignition (LOI) determined by measuring weight loss of a sample heated to 800°C. The composition of the invention product contains about 1.5 to 4.0 moles of Si0 2 for each mole of M 2 0 wherein M can be sodium and/or potassium. The product is amorphous to x-rays. Among the properties that make the invention product desirable as a detergent ingredient are its mag¬ nesium exchange capacity and its absorption of liquids. Our product can sequester at least 2 milliequivalents of Mg per gram of anhydrous product. It can sorb 30 to 50% by weight of liquids, such as surfactants. These properties are provided by products with a Si0 2 /M 2 0 ratio of about 1.5 to 3.0. The particulate silicate product of the invention is useful for any application that requires a solid amor¬ phous silicate of a water content that is considerably below that available with present commercial products. The hydrated product of this invention is especially useful in detergent and cleaning compounds. It is advantageous to use our product in combination with other builder materials known to be effective in reducing the calcium activity in washing baths. Since this product provides desirable additional alkalinity and corrosion control, it is useful to include it in detergent formulations with other builders such as condensed phosphates, NTA, citric acid, carbonates, layered silicates, polycarboxylates, zeolites and the like. A detergent builder combination of zeolite A and our expanded pulverized silicate product is particularly desirable for laundry detergents. The ion exchange prop¬ erties of zeolite A are such that it removes calcium ions from hard water wash baths effectively, but it is relative- ly ineffective in removing magnesium ions. The combination of zeolite A and the product of this invention provides effective removal of hardness ions from solution while providing additional detergent properties. The proportions of zeolite NaA and the product of our invention can be any that sequester the calcium and magnesium hardness ions present in the washing bath. In addition, the high liquid loading possible with the invention product is an advantage for either laundry detergents or dishwashing detergents made by agglomeration and post blending methods. The foamed and expanded silicate and the hydrated particles of our invention are also useful for other applications requiring silicate materials. For example, they can be included in cements and in particular certain acid-resistant cements as part of the setting agent. They are also a suitable material for the preparation of other silicate containing materials such as aluminosilicates and crystalline silicate. EXAMPLES The following non-limiting examples illustrate several embodiments of our invention. These examples are not provided to establish the scope of the invention, which is described in the disclosure and recited in the claims. The proportions in the examples are in parts by weight (pbw) , percent by weight, parts per million (ppm) , moles or equivalents. The calcium and magnesium ion ex¬ change rates and capacities were determined for various products and are reported as the calcium exchange rate (CER) , calcium exchange capacity (CEC) , magnesium exchange rate (MgER) and magnesium exchange capacity (MgEC) . These results are expressed as milligrams (mg) of CaC0 3 /gram (g) of anhydrous product for both calcium and magnesium. Such reporting practice is common in the detergent industry. The magnesium exchange capacity is described in the dis¬ closure and recited in the claims as milliequivalents of Mg per gram of anhydrous product for brevity. The calcium and magnesium performance (CER, CEC, MgER and MgEC) were determined as follows. The product (0.5 grams on an anhydrous basis) was reacted with 250 milliliters (ml) of a solution containing either calcium or magnesium ions. The concentration of these solutions was 1000 ppm expressed as CaC0 3 . The stirred reaction mixture was buffered at pH 10 with 2 to 3 mis of a solution of NH 4 C1 and NH 4 OH. The temperature was held at 25°C during the titration. An aliquot (15 ml) was removed after 2 minutes to determine the CER or MgER by pulling the suspension through a 1.0 micron filter into a syringe. A second aliquot was removed at 15 minutes to determine the CEC or MgEC. The filtrates were analyzed for calcium in solu¬ tions as follows. A 5 ml aliquot of filtrate was combined with 5 ml of 1 molar NaOH and about 100 milligrams of Hydroxy Naphthol Blue indicator. A titration to a definite blue endpoint was carried out with 0.005 molar ethylene diaminetetracetic acid (EDTA) and the volume of EDTA recorded. A blank titration using 5 ml of the 1000 ppm CaC0 3 solution was carried out using the same method and the volume of EDTA recorded. Filtrates were analyzed for Mg in the same manner except that 5 ml of an NH 4 0H/NH 4 C1 buffer and about 100 mg Erichrome Black T indicator were used. The rates and capacities for calcium or magnesium ions in solution were calculated as mg of CaC0 3 /g of product as follows: mi lli% s o£""- [<- V > * » * * » * 50 ]/(««=«* ) W B = volume of EDTA for blank titration (ml) V = volume of EDTA for sample titration (ml) M = Molarity of EDTA solution FW = Formula weight of CaC0 3 (lOO.lg/mole) LOI = Loss on Ignition of product at 800°C (%) W = Weight of product (grams) Liquid loading was determined as follows. A sample of the product (5g) was combined with a known amount of liquid, usually a surfactant containing 0.1% of Calcozinc Rhodamine BX dye. If necessary, the liquid-dye combination was heated to 30°C prior to use. The mixture was agitated for 30 seconds using a spatula; then the mixture was placed in a closed bottle and shaken gently for an additional 30 seconds. After a 15 minute quiescent aging period, the sample was poured onto a piece of white photocopy paper to form a compact heap having a 2.5 inch diameter base. After 3 minutes the mixture was removed from the paper which was allowed to dry for an hour. If red spots were not ob¬ served, the test was repeated with an increased amount of liquid. When significant red spotting was observed the sample was not holding the liquid, and the test was re¬ peated using less liquid. The liquid loading in percent by weight was determined based on the weight of liquid sorbed by the product on an anhydrous basis. The amorphous crystalline or partially crystalline nature of the materials generated in the examples was determined using standard x-ray diffraction techniques. A 5-50 20 scan was used. Examples 1-6 Eight pbw of ground sodium silicate glass of various Si0 2 /Na 2 0 ratios was mixed vigorously with 2 pbw of deionized, distilled water for 10 minutes. No heating or cooling was supplied during mixing. The resulting mixture was held at room temperature for 15 minutes. The mixture was then heated at a rate of 5°C/min to 400°C and held at 400°C for 10 minutes. The resulting foamed and expanded material was allowed to cool to room temperature and then milled easily to a particle size below about 20μ. The milled material was hydrated in a 75% relative humidity chamber until a product with a LOI of 1 to 4% was attained. The products were tested for crystallinity using x-ray diffraction (XRD) . CER, CEC, MgER, MgEC and surfactant loading were determined as described above. The variations of Si0 2 /Na 2 0 in the glass and the properties measured are summarized in Table 1. TABLE 1 Preparing Products from Glasses of Various Siθ-/Na 2 θ Ratio SiO j /Na LOI XRD Surfactant Example (wt wt) CER* CEC* MgER* MgEC* Remit Loading** («) 1 1.50 88 176 415 474 2.3 Amorphous 30-40 2 1.70 44 132 367 470 2.7 Amorphous 30-40 3 2.00 24 24 206 357 2.9 Amorphous 40-50 4 2.40 18 21 81 242 1.6 Amorphous 30-35 5 2.75 20 30 40 150 1.4 Amorphous 40 6 3.22 35 35 25 90 2.1 Amorphous 40 *units are mg CaCO j /g anhydrous product **Neodol 25-7 These results indicate that the expanded product can be prepared from silicates of various ratios of Si0 2 /Na 2 0 but that products useful in controlling magnesium ion in solution will have Si0 2 /Na 2 0 weight ratios of about 1.5 to 2.5. Examples 7-12 Mixtures of 8 pbw of sodium silicate glass (2.0 moles of Si0 2 per mole of Na 2 0) and 2 pbw of water were prepared, heated, milled and hydrated as described in Examples 1-6, except that the heating temperature was varied. The mixtures were heated at 5°C per minute to temperatures between and including 250 to 500°C. The results of these tests are summarized in Table 2. TABLE 2 Preparing Products at Various Temperatures Temperature LOI Example ( °C) MgER* MgEC* ( % ) XRD Result 7 250 100 269 4.35 Amorphous 8 300 225 363 3.6 Amorphous 9 350 211 349 3.1 Amorphous 10 400 206 357 2.9 Amorphous 11 450 — — — Partly Crystalline 12 500 — — — Partly Crystalline *units are mg CaC0 3 /g anhydrous product The results indicate that the preferred amorphous product of the invention was obtained when temperatures of about 300 to about 400°C were used. Examples 13-15 Mixtures of ground sodium silicate glass (2.0 Si0 2 /Na 2 0) and water were prepared, heated, milled and hydrated as described in Examples 1-6, except that various proportions of ground glass and water were used. The results are summarized in Table 3. TABLE 3 Preparing Products Using Different Amounts of Water GLASS WATER LOI Example * (pbw) (pbw) CER* CEC* MgER* MgEC* (*) XRD Result 13 9.5 0.5 44 54 156 329 2.2 Amorphous 14 9.0 1.0 29 34 186 342 2.4 Amorphous 15 8.5 1.5 24 30 210 362 2.2 Amorphous 3 8.0 2.0 24 24 206 357 2.9 Amorphous *units are mg of CaCO j /g anhydrous product These results indicate that useful products can be made if sufficient water is present to induce foaming upon heating of the glass-water mixture to a temperature of about 300 to 400°C. Mixtures that contain more water do not provide useful products. Examples 16-18 Mixtures of ground sodium silicate glass (2.0 Si0 2 /Na 2 0) and water were prepared, heated, milled and hydrated as described in Examples 1-6, except that the mixtures were held (aged) for different periods of time after forming the mixture but prior to heating. The results are summarized in Table 4. TABLE 4 Preparing Product at Various Aging Times LOI Example Aging Time* MgER** MgEC** (%) XRD Result 16 15 min. 206 357 2.9 Amorphous 17 2 hours 210 346 2.7 Amorphous 18 24 hours 205 340 3.1 Amorphous *at room temperature **units are mg CaC0 3 /g anhydrous product These results indicate that the aging time of the glass-water mixture did not significantly alter the properties of the invention product. Examples 19-22 Mixtures of ground sodium silicate (2.0 Si0 2 /Na 2 0) and water were prepared, heated, milled and hydrated as described in Examples 1-6, except that the heating rate to 400°C was varied. These heating rates and the results are summarized in Table 5. TABLE 5 Preparing Product at Various Heating Rates Heating Rate to 400 °C LOI Example (C/min) MgER* MgEC* (%) XRD Result 19 0.5 188 330 1.3 Amorphous 20 5 206 357 2.9 Amorphous 21 10 ND ND ND Amorphous 22 15 188 334 3.5 Amorphous *units are mg CaC0 3 /g anhydrous product ND = Not Determined Results are discussed with the result obtained in Example 23. Example 23 A mixture of 8 pbw of sodium silicate glass (2.0 Si0 2 /Na 2 0) and 2 pbw of water was prepared and aged for 15 minutes prior to heating. The mixture was exposed immedi¬ ately to 400°C. The mixture foamed as usual after a short induction period. The milled expanded product hydrated to an LOI of 2.7% was found comparable to other products with a MgER of 208 and a MgEC of 338 expressed as mg of CaC0 3 /g anhydrous product. This result combined with those of Examples 19-22 indicate that various heating programs can be used to prepare the product of our invention. Examples 24-27 Mixtures of ground sodium silicate glass (2.0 Si0/Na 2 0) and water were prepared, heated, milled and hydrated as described in Examples 1-6, except that the time of exposure to a temperature of 400°C was varied. These times and the results are summarized in Table 6. TABLE 6 Preparing Product Using Various Heating Times Heating Surfactant Time LOI Loading** Example @ 400°C MgER* MgEC* (%) XRD Result (%) 24 10 min 206 357 2.9 Amorphous 40-50 25 30 min ND ND ND Amorphous ND 26 1 hr 192 323 2.6 Amorphous ND 27 12 hrs 185 310 1.1 Amorphous 30 *units are mg CaC0 3 /g anhydrous product **Neodol 25-7 ND = Not Determined These results indicate that the heating time at a temperature of 400°C is only limited by efficient production. Examples 28-31 Mixtures of ground sodium silicate glass (2.0 Si0 2 /Na 2 0) and water were prepared, heated, milled and hydrated as described in Examples 1-6, except that the products were adjusted to various LOI levels by exposure to 75% relative humidity. These moisture levels and the results are summarized in Table 7. TABLE 7 Preparing Product at Various Water Contents LOI Example (%) CER* CEC* MgER* MgEC* XRD Result 28 0 12 27 150 250 Amorphous 29 1.50 19 25 225 335 Amorphous 30 3.50 20 31 233 341 Amorphous 31 15.41 25 34 253 360 Amorphous *units are mg CaC0 3 /g anhydrous product The results of Example 28 show that the anhydrous product formed by heating is not useful as a potential detergent ingredient. Surprisingly, the hydration of the products to LOI levels of about 1.0% or greater results in extremely useful materials. Examples 32-34 Mixtures of ground sodium silicate glass (2.0 Si0 2 /Na 2 0) and water were prepared, heated, milled and hydrated as described in Examples 1-6 except that the particle size of the ground glass was varied. These particle sizes and the results obtained are summarized in Table 8. TABLE 8 Preparing Product From Glasses of Various Particle Sizes Particle Size Range LOI Example (μm) ** MgER* MgEC* ( % ) XRD Result 32 <75 206 375 2.9 Amorphous 33 125-150 169 370 1.9 Amorphous 34 212-250 164 336 1.6 Amorphous *units are mg CaC0 3 /g anhydrous product **determined using U. S . Series sieves Examples 35-38 A product prepared as described in Example 3 was tested for sorption of various liquids as described previously. The results are summarized in Table 9. TABLE 9 Liquids Sorbed by Product Liquid Loading Example Liquid Sorbed (%) 35 Mineral Oil 35-40 36 Triton ® X-100 30-35 37 Triton ® N-101 30-35 38 Neodol ® 23-3 25-30 3 Neodol ® 25-7 40-50 These results indicate that various liquids are sorbed by the product of our invention in substantial amounts. Examples 39-42 Mixtures of ground alkali metal silicate glass (2.0 moles Si0 2 /mole of M 2 0) were prepared, heated, granulated and hydrated as described in Examples 1-6, except that M 2 0 was Na 2 0 + K 2 0 as summarized in Table 10. These results show that glasses with mixtures of sodium and potassium ions can be processed and form de¬ sirable products. Example 43 A mixture of 8 pbw ground sodium silicate glass (2.0 Si0 2 /Na 2 0) and 2 pbw water was prepared, heated, milled and hydrated as described in Example 18 except that an acid solution containing 0.2 pbw of 2N HC1 and 1.8 pbw of water was substituted for the water. The resulting material having an LOI of 2.47% was tested and had a MgER of 249 and a MgEC of 384 expressed as mg of CaC0 3 /gram of anhydrous product. Example 44 A mixture of 8 pbw of ground sodium silicate glass (2.0 Si0 2 /Na 2 0) and 2 pbw water was prepared, heated, milled and hydrated as described in Example 18 except that the water contained NaOH. The solution contained 0.17 pbw of NaOH and 1.83 pbw of water. The resulting material had a MgER of 250 mg CaC0 3 /g of anhydrous product and a MgEC of 377 mg CaC0 3 /g of anhydrous product at an LOI of 2.0 and had a Si0 2 /Na 2 0 ratio of 1.9. Example 45 The excellent stability of our invention product compared to spray dried materials was demonstrated by a heating test. Our product prepared as described in Example 3 and a spray dried sodium silicate (2.0 Si0 2 /Na 2 0 and 20% water) were placed in sealed containers and subjected to heating to 50°C for 14 hours and cooled to room temperature for 10 hours. After 2 cycles, the spray dried material formed a dense cake, while the product of our invention remained free flowing. Example 46 A product prepared as described in Example 3 was tested as a detergent builder and as a co-builder with zeolite NaA under the following conditions using a Terg-o- Tometer ® at 100 cycles per minute: Water Hardness: 150 ppm (2:1 Ca/Mg ratio) Dissolve Time: 2 min Wash Time: 10 min Rinse Time: 5 min Soiled Cloth Load: two swatches each of cotton, polyester, and cotton-polyester blend* soiled with dust-sebum two swatches each of cotton, polyester, and cotton-polyester blend* soiled with ground-in clay one swatch each of cotton, polyester, and cotton-polyester blend* unsoiled Surfactant: Linear Alkyl Sulfonate *50% cotton/50% polyester with a durable press finish The cleaning effectiveness of each formulation was determined with a Hunter Colorimeter using the L scale (whiteness) to approximate the response of the human eye. The pre-washed clean cloths and pre-washed soiled cloths were used as limiting standards for determining ΔL for each fabric type. An average percent increase in reflectance (ΔL) was determined for each pair of similar soil-cloths within a wash-pot. The reported ΣΔL values are the sums of the ΔL scores for all three fabric types similarly soiled within one wash-pot. Ground-in clay and dust/sebum scores are reported separately. The results are summarized in Table 11 and indicate clearly that the cleaning performance provided by a combination of zeolite NaA and our invention silicate product is very good over a broad range of temperatures. For the particular conditions of this test, the effective proportions of zeolite Na-A and our product appear to be 50 to 75 pbw of zeolite and 25 to 50 pbw of our product. Example 47 Eight pbw of ground potassium silicate glass (Si0 2 /K 2 0 = 2.5 weight ratio) was mixed vigorously with 2 pbw of water and the resulting mixture was aged 15 minutes. The aged glass/water mixture was heated to 400°C at 5°C/minute and held at this temperature for 10 minutes. The resulting foam and expanded material was allowed to cool to room temperature and then milled easily to a particle size below about 20μ. The milled material was hydrated in a 75% relative humidity chamber until a product with a LOI of 3 to 5% was attained. The resulting product was amorphous. The MgER was 90 mg CaC0 3 /g of anhydrous product and MgEC was 155 CaC0 3 /g of anhydrous product. TABLE 10 Preparing Product With Various Alkali Metal Composites Surfactant Example M 2 0 CER CEC MgER* MgEC* LOI XRD Result Adsorption (%)** 39 0.95 Na 2 O+0.05 K 2 0 31 41 245 352 1.8 Amorphous 30-35 40 0.9 Na 2 O+0.1K 2 θ 24 39 235 362 1.6 Amorphous 30-35 41 0.8 Na 2 O+0.2K 2 O 20 34 251 379 1.3 Amorphous 30-35 42 0.7 Na 2 O+0.3K 2 O ND ND ND ND ND Amorphous ND *units are mg CaC0 3 /g anhydrous product **Neodol 25-7 10 ND = not determined OO TABLE 11 Product as Builder and Co-builder for Detergent Builder System 10°C 20°C 40°C 60°C Silicate Product/Z NaA 1 15 pbw/pbw D-S 2 G-C 3 D-S G-C D-S G-C D-S G-C 100/0 24.60 32.60 24.30 32.20 35.95 34.95 35.40 32.75 75/25 29.95 33.85 39.90 36.80 40.60 39.50 39.86 38.60 50/50 38.40 39.80 48.70 39.50 49.25 43.25 44.00 39.35 25/75 39.90 41.40 44.15 40.55 51.00 46.10 46.75 41.35 20 0/100 28.15 41.75 29.50 43.10 30.45 44.75 24.55 38.15 Co-Builder Concentration = 0.65 grams/liter LAS Concentration = 0.35 grams/liter 'ZNaA = Zeolite NaA 2 D-S = Dust-Sebum Total (cotton, polyester + cotton-polyester) 25 3 G-C = Ground-In Clay (cotton, polyester + cotton-polyester) Example 48 An acid resistant refractory can be prepared from a cement having a composition of 80 to 90 pbw of filler and 10 to 20 pbw of the essentially anhydrous alkali metal silicate particles having a particle size of below about 20μ produced as an intermediary in any of Examples 1 through 6. The filler for such a cement can be selected from the group consisting of raw fire clay, calcined fire clay, mullite or alumina or combinations thereof. Example 49 An acid resistant refractory can be prepared from a cement having a composition of 80 to 90 pbw of filler and 10 to 20 pbw of the essentially anhydrous alkali metal silicate particles having a particle size below about 20μ produced as an intermediary in any of Examples 39 through 42. The filler for such a cement can be selected from the group consisting of raw fire clay, calcined fire clay, mullite or alumina or combinations thereof.

Claims: CLAIMS We claim: 1. Hydrated amorphous alkali metal silicate part¬ icles comprising 1.5 to 4.0 moles of Si0 2 for each mole of M 2 0 wherein M is sodium and/or potassium, and 0.5 to 15 per¬ cent by weight water, having a magnesium exchange capacity of more than about 2 milliequivalents of Mg per gram of anhydrous silicate, having the capacity to sorb 30 to 50 percent by weight of liquid nonionic surfactant, and having a particle size of less than 20 microns. 2. The hydrated amorphous alkali metal silicate of claim 1. wherein the water content ranges from 1 to 15 percent by weight. 3. The hydrated amorphous alkali metal silicate of claim 1. wherein the water content ranges from 1 to 12 percent by weight. 4. A process for producing the hydrated amorphous alkali metal silicate particles of claim 1 which comprises the steps of: a. forming a mixture of (1) alkali metal silicate glass and (2) water or (3) an aqueous solution of i. an alkali metal silicate and/or an alkali metal hydroxide or ii . a mineral acid b. exposing the mixture of step a. to a temperature of about 300 to about 400°C for a period of time sufficient to cause the mixture of glass and water or aqueous solution to foam and expand; c. cooling the foam of step b. and subjecting the cooled foam to fracturing conditions under which particles of less than 20 microns are formed from the foam; d. subjecting the particles of step c. to an atmosphere of moisture under conditions sufficient to provide a hydrated product containing 1 to 15 percent by weight of water based on loss on ignition (LOI) of product at 800°C; and e. recovering the hydrated amorphous alkali metal silicate product. 5. A process of preparing hydrated amorphous alkali metal silicate particles comprising the steps of: a. forming a mixture of (1) alkali metal silicate glass and (2) 5 to 20% by weight water or (3) an aqueous solution containing 5 to 20% water on a weight basis of i. an alkali metal silicate and/or an alkali metal hydroxide or ii . a mineral acid b. heating the mixture of step a. to a temperature of about 300 to about 400°C for a period of time suffi¬ cient to cause the mixture of glass and water or aqueous solution to foam and expand; c. cooling the foam to a temperature at which the foam formed into particles and subjecting the cooled foam to fractioning conditions under which particles of less than 20 microns are formed; d. subjecting the particles obtained in step c. to a moist atmosphere under conditions which form a hydrated product containing 1 to 15 percent by weight of water based on loss on ignition (LOI) of the product at 800°C; and e. recovering the hydrated amorphous alkali metal silicate product. 6. A process according to claim 5. wherein the cooled foam in step c. is milled to form the particles. 7. A process according to claim 5. wherein in step c. the foam is mixed with water to rapidly cool the foam and cause shattering and formation of the particles. 8. A washing or cleaning composition containing effective amounts of surfactants and a builder system wherein the builder system comprises a builder agent ef¬ fective in reducing activity of calcium in solution, a particulate hydrated amorphous alkali metal silicate com¬ prising 1.5 to 4.0 moles of Si0 2 per mole of M 2 0 wherein M is sodium and/or potassium and 0.5 to 15 percent by weight water based on loss of ignition (LOI) of product at 800°C, having a magnesium exchange capacity of more than about 2 milliequivalents of Mg per gram of anhydrous silicate, hav¬ ing the capacity to sorb 30 to 50 percent by weight of liquid nonionic surfactants, and having a particle size less than 20 microns. 9. A washing or cleaning composition of claim 8. wherein the builder system includes zeolite A as the builder agent which is effective in reducing the activity of calcium in solution. 10. The washing or cleaning composition of claim 9. wherein said builder system consists of about 50 to 75 parts by weight (pbw) of zeolite A and about 25 to 50 pbw of said amorphous alkali metal silicate. 11. A washing or cleaning composition according to claim 8. wherein the hydrated amorphous alkali metal silicate is prepared by the steps of: a. forming a mixture of alkali metal silicate glass and 5 to 20 percent by weight water; b. exposing said mixture to a temperature of about 300 to about 400°C for a period of time sufficient to cause the mixture of glass and water to foam and expand; c. cooling the foam and subjecting same to fracturing conditions under which particles of less than 20 microns are formed; d. subjecting the particles formed in step c. to suffi¬ cient moisture under conditions which form a hydrated product containing 1 to 15 percent by weight of water based on loss of ignition (LOI) of product at 800°C; and e. recovering the hydrated amorphous alkali metal silicate formed in step d. 12. A washing or cleaning composition according to claim 10. wherein the hydrated amorphous alkali metal silicate is prepared by the steps of: a. forming a mixture of alkali metal silicate glass and 5 to 20 percent by weight water; b. exposing said mixture to a temperature of about 300 to about 400°C for a period of time sufficient to cause the mixture of glass and water to foam and expand; c. cooling the foam and subjecting same to fracturing conditions under which particles of less than 20 microns are formed; d. subjecting the particles formed in step c. to suffi¬ cient moisture under conditions which form a hydrated product containing 0.5 to 15 percent by weight of water based on loss of ignition (LOI) of product at 800°C; and e. recovering the hydrated amorphous alkali metal silicate formed in step d. 13. The washing or cleaning composition of claim 11. wherein the water recited in step a. is present in the foam of a solution of a mineral acid, NaOH, KOH, sodium silicate or potassium silicate or mixtures of the alkaline material. 14. The washing or cleaning composition of claim 12. wherein the water recited in step a. is present in the form of a solution of an acid, NaOH, KOH, sodium silicate or potassium silicate. 15. A process according to claim 5. wherein the mixture in step a. is alkali metal silicate glass and water. 16. Alkali metal silicate particles prepared by the method comprising: a. forming a mixture of (1) alkali metal silicate glass and (2) water or (3) an aqueous solution of i. an alkali metal silicate and/or an alkali metal hydroxide or ii . a mineral acid b. exposing the mixture of step a. to a temperature of about 300 to about 400°c for a period of time sufficient to cause the mixture of glass and water or aqueous solution to foam and expand; and c. cooling the foam of step b. and subjecting the cooled foam to fracturing conditions under which particles of less than 20 microns are formed from the foam. 17. A process for producing essentially anhydrous alkali metal silicate particles comprising 1.5 to 4.0 moles of Si0 2 for each mole of M 2 0 wherein M is sodium and/or potassium, and less than 1% by weight water, having a magnesium exchange capacity of more than about 2 milli¬ equivalents of Mg per gram of anhydrous silicate, and having a particle size of less than 20 microns which comprises the steps of: a. forming a mixture of (1) alkali metal silicate glass and (2) water or (3) an aqueous solution of i. an alkali metal silicate and/or an alkali metal hydroxide or ii . a mineral acid b. exposing the mixture of step a. to a temperature of about 300 to about 400°C for a period of time sufficient to cause the mixture of glass and water or aqueous solution to foam and expand; and c. cooling the foam of step b. and subjecting the cooled foam to fracturing conditions under which particles of less than 20 microns are formed from the foam.

Inventors: BORGSTEDT ERIC V R, DENKEWICZ RAYMOND P, BORGSTEDT, ERIC, V., R., DENKEWICZ, RAYMOND, P.
Applicants: PQ CORP, PQ CORPORATION
Application year: 1994
Main classification: C01B33
IPC codes: B01J20, C01B33, C11D3